Mechanical combining apparatus



July 25, 1967 Fi led March 17, 1966 M. A G REULICH MECHANICAL COMBININGAPPARATUS 5 Sheets-Sheet 1 MAX A. GREQL/GH INVENTOR.

TTOR/VEY July 25, 1967 M. A. GREULICH I 3,332,530

MECHANICAL COMB INING APPARATUS Filed March 17, 1966 5 Sheets-Sheet 262' I l ulll hl """HNINII Mi" MAX A. GREUL/GH INVENTOR.

J y 1957 M. A. GREULICH 3,332,530

MECHANICAL COMBINING APPARATUS Filed March 17, 1966 5 Sheets-Sheet 5dlllllll.

Iii m WIN l: Milli! MAXA. GREUL/Of/ INVENTOR.

July 25, 1967 M. A. GREULICH 3,332,530

MECHANI CAL COMB INING APPARATUS MAX A. GREUL/GH INVENTOR.

ATTORNEY-V July 25, 1967 M. A. GREULICH MECHANICAL COMBINING APPARATUS 5Sheets-Sheet Filed March 17, 1966 MAX A. GREUL/GH INVENTOR B W- TORNEYUnited States Patent 3,332,530 MECHANICAL COMBINING APPARATUS Max A.Greulich, Montclair, N.J., assiguor to Wilhelm B. Bronander, Jr.,Montclair, NJ. Filed Mar. 17, 1966, Ser. No. 535,100 8 Claims. (Cl.198-32) ABSTRACT OF THE DISCLOSURE Apparatus for receivingrandomly-spaced cartons from two conveyor supply lines and automaticallydischarging the cartons in a single line. Control members are actuatedin a mutually-exclusive manner by the incoming cartons to preventjamming of the cartons as they are moved to the in-line positions.

This invention relates to a mechanical combining apparatus and moreparticularly to apparatus for receiving objects carried in haphazardsequence on two conveyor lines and automatically discharging the objectsin a single line.

Although apparatus made in accordance with this invention is adapted foroperation with objects of any size and shape, it will be describedspecifically for use with cartons. In various packaging operations,cartons are transported through a production line on conveyors. Often,two conveyors run parallel to each other and the spacings betweencartons carried by each conveyor are not uniform. At some other stationin the production line, it is advantageous to combine the cartons fromboth conveyors into a single in-line flow. This is accomplished byapparatus generally referred to as a carton combiner.

Presently available carton combiners operate at relatively low speeds,are of complex construction and require considerable maintenance. 7

An object of this invention is the provision of a carton combiner ofimproved construction and increased operating speed.

An object of this invention is the provision of apparatus adapted toreceive randomly-spaced objects from two conveyor supply lines andautomatically discharging the objects in a single line, which apparatusincludes control means actuated by movement of the objects and effectiveto provide a predetermined spacing between objects alternately receivedfrom the two lines, thereby to prevent jamming of the objects as theyprogress to the discharge end of the apparatus.

An object 'of this invention is the provision of carton combiningapparatus comprising an endless belt for receiving cartons from twoconveyor lines, a control station at the receiving end of said belt,means defining two parallel paths from the flow of the cartons throughthe control station, individual carton-actuated control members normallyextending into the path of travel of the cartons as they pass throughthe control station, means effective upon actuation of one of thecontrol members to mechanically lock the other control member in itsnormal position, and guide means for directing cartons which have passedthrough the control station into a single line at the other end of thebelt.

These and other objects and advantages of the invention will becomeapparent from the following description when taken with the accompanyingdrawings. It will be understood, however, that the drawings are forpurposes of illustration and are not to be construed as defining thescope or limits of the invention, reference being had for the latterpurpose to the claims appended hereto.

In the drawings wherein like reference characters denote like parts inthe several views:

FIGURE 1 is a fragmentary top plan view showing 3,332,530 Patented July25, 1967 apparatus of the class to which this invention is directed,with parts shown diagrammatically;

FIGURE 2 is a corresponding side elevational view;

FIGURE 3 is an enlarged, top plan view of the super structure carryingthe various components constituting the control station in accordancewith this invention;

FIGURE 4 is an end elevational view thereof, as viewed from the left endof FIGURE 3;

FIGURE 5 is a cross-sectional view taken along the line 55 of FIGURE 3;

FIGURE 6 is an isometric view of a horizontal gate bar forming a part ofone carton-actuated control arm;

FIGURE 7 is an isometric view of the associated gate having a curled endportion for engagement by a carton carried by the belt;

FIGURE 8 is a top plan view of the lock-out arm;

FIGURE 9 is a side elevational view thereof;

FIGURE 10 is an end elevational view thereof;

FIGURE 11 is a fragmentary, top plan view showing a modifiedconstruction of the control station;

FIGURE 12 is a cross-sectional view taken along the line 1212 of FIGURE11; and

FIGURE 13 is a corresponding side elevational view.

Referring now to FIGURES 1 and 2, the combiner apparatus comprises abase 10 carrying a synchronous motor 11 and a gear reduction unit 12 andhaving four upstanding struts 13-16 welded thereto. A pair of cross bars17 and 18 are secured to the struts, said cross bars having ends weldedto the parallel side frames 19 and 20. An endless belt 21 is disposedbetween the side frames and passes around the end rollers 22 and 23, theroller 23 having secured thereto a sprocket which is coupled to the gearreduction unit by a drive chain 24. In accordance with conventionalpractice, the upper surface of the belt is supported by a plurality ofidler rollers rotatably carried by the side frames. A pair of inverted,U-shaped brackets 25 and 26 have ends welded to the side frames andserve as supports for the two guide rails 27 and 28 which are spacedabove the belt. The central portions of the guide rails converge andterminate in parallel end portions at the delivery end of the belt, thatis, the left end of the apparatus. The other parallel end portions ofthe guide rails are spaced apart a distance somewhat less than the widthof the belt. Although not shown in FIGURES 1 and 2, these end portionsof the guide rails are secured to a super structure generally identifiedby the numeral 30. Such super structure also has secured thereto a pairof short inner guide rails 31 and 32 to define parallel flow paths forthe cartons passing through the control station.

The described apparatus may be mounted on the floor or it may besuspended from a ceiling by means of suitable suspensions. In eithercase, the belt 21 is aligned with two conveyor lines designated Line Aand Line B in FIG- URE 1. In operation, cartons 35a and 35b aretransferred onto the belt 21 in a haphazard sequence. The transferredcartons are guided in their movement under the super structure 30 by theguide rails 31 and 32 and the associated ends of the guide rails 27 and28. Thereafter, the cartons converge into a single line, under theinfluence of the central portions of the guide rails 27 and 28, and aredischarged onto a gravity conveyor 36, In order to prevent a jamming ofthe cartons as they are transported toward the discharge end of theapparatus, it is necessary to provide a staggered movement of the carbonas they are transported to and along the converging portions of theguide rails 27 and 28. This is accomplished by means of a controlmechanism carried by the super structure 30 and constituting a controlstation, which mechanism will be described in detail hereinbelow, Forthe present, it is pointed out that a pair of pivotallymounted actuatingarms are carried by the super structure, each arm having adownwardly-depending end normally extending into the path of travel ofthe cartons as they pass under the super structure, one such arm 37being shown in the side elevational view of FIGURE 2. The controlmechanism includes a lock-out arrange ment whereby the actuating armsoperate in a mutually exclusive manner. Specifically, upon rotation ofthe actuating arm 37 by a carton 35a in Line A, the other actuating armis locked in its normal position, thereby preventing a Line B cartonfrom moving beyond the super structure. Upon passage of the Line Acarton beyond the actuating arm 37, this arm is returned to its normalposition, thereby unlocking the actuating arm associated with the Line Bcartons. This permits the Line B carton to move with the belt, therebyrotating the associated actuating arm and simultaneously locking theactuating arm 37 in its normal position, thereby blocking movement ofthe next-following Line A carton. Thus, it will be apparent that thealternate release of cartons received from the two infeed conveyorsresults in a spacing of the released cartons, taken axially of the belt21, which spacing exceeds the length of the particular cartons, therebyresulting in a single in-line flow of the cartons onto the conveyor 36.Such spacing of the cartons will depend upon the mechanical movement ofthe actuating arms to effect the described locking and unlocking actionand the linear speed of the belt 21. It may also here be pointed outthat when the cartons in one of the infeed lines are disposedback-to-back in a group, this entire group will pass through thecombiner apparatus before the cartons in the other line are released.

The mechanism for automatically controlling the flow of the cartonsthrough the control station will now be described with specificreference to FIGURES 3-5, FIG- URE 3 being a top plan view, FIGURE 4 anend elevational view as viewed from the left side of FIGURE 3, andFIGURE 5 being a cross-sectional view taken along the line 55 of FIGURE3. The super structure 30 is an open frame structure formed of the upperhorizontal angle irons 39-42, the four long vertical angle irons 43-46,the two short vertical angle arms 47 and 48, the front vertical plate 49and the rear vertical plate 50. These members are welded together toform a sturdy, rigid structure. The lower ends of the four verticalangle irons 43-46 are secured to the spaced side frames 19 and 20 whichcarry the belt 21, as by means of angle brackets, bolts and nuts,whereby the entire super structure, as well as the control mechanism,readily may be removed from the belt assembly.

The horizontally-disposed angle irons 51 and 52, extendinglongitudinally of the belt 21, have their ends welded to the twovertical plates 45 and 50. These angle irons carry two sets of alignedbearings, namely, the bearings 53, 54 and 55, 56. Similar angle irons 57and 58 carry the end bearings 59 and 60, see particularly FIG- URES 3and 4. A shaft 61 is freely rotatable within the bearings 53 and 59,said shaft being provided with an axial keyway for securing thereto thehorizontal gate arm 62, which gate arm has secured thereto the gate 63,as by the two bolts 64 and cooperating nuts. It is here pointed out thatthe assembled gate and gate arm are the members constituting theactuating arm 37 referred to above and shown diagrammatically in FIGURE2.

As shown in the isometric view of FIGURE 6, the gate arm 62 comprises ahollow, metal housing 65, of rectangular configuration and open at bothends. Two metal tubes 66 span the housing and have ends disposed inaligned holes formed in the housing side walls. The ends of the tubesare welded to the housing walls. Disposed within the housing is a metalblock 67 secured by four rivets 68 passing through aligned holes formedin the block and the top and bottom walls of the housing. A transversekeyhole 69 is formed in the housing side walls and the block, thecircular portion of such hole having a diameter for receiving the shaft61, see FIG- 4 URE 3. A steel key driven into the keyway of the shaftand the keyhole of the gate arm secures the arm firmly to the shaft. Aflat, flexure spring 70 has an end clampingly secured to the gate arm 62by a bar 71 and screws 72.

The construction and configuration of the associated gate 63 is shown inthe isometric view of FIGURE 7. Such gate comprises spaced, verticalside walls 73 joined to a base portion 74 having an extended, curled end75. The set of aligned holes 76, formed in the side walls, are alignedwith the tubes 66, of the gate arm, when the gate is slidably positionedover the forward end of the gate arm so that these two members can besecured together by the two bolts 64 and cooperating nuts, as shown inFIGURES 3-5. When so assembled, the free end 75 of the gate extends intothe path of the carton 35a carried by the belt 21, see particularlyFIGURE 5. A second set of holes 77, formed in the side walls of thegate, provide a means for lowering the free end of the gate, thereby toadapt the apparatus for use with cartons of smaller height. Additionalholes can be rovided to adapt the apparatus for operation with a widerrange of carton sizes.

Referring to FIGURES 3 and 5, the free end of the flexure spring 70 isslidable between the horizontal arm of an L-shaped bracket and a flatbar 81 secured thereto by the two bolts 82 and cooperating nuts, thebracket 80 being welded or otherwise secured to a transverse flat bar 83having its ends welded to the two short vertical angle irons 47 and 48.A locking lever 85, having a spacing bushing 86 welded thereto, issecured to the end of the shaft 61 by means of conventional keyways anda key. As best seen in FIGURE 3, formed in the free end of this lever isa detent 87 :defined by a semi-circular bottom wall. The describedassembly of the gate 63, the gate arm 62, the shaft 61 and the lockinglever is rotatable as a unit when the curled end 75 of the gate isengaged by the moving carton 35a. The assembly will remain in therotated position until the carton passes beyond the gate end, afterwhich the flexure spring 70 returns the assembly to the normal position,as illustrated.

The described construction of the gate and gate arms provides requiredstrength with minimum weight. The weight of the members carried by theshaft 61 is counterbalanced by the flexure spring thereby to providehigh sensitivity and speed of action.

It will be apparent the described gate and gate arm are associated withthe cartons transported by the belt 21 and received from the infeedconveyor of Line A, see FIGURE 1. A similar, carton-actuated assembly isassociated with the cartons supplied by the infeed conveyor line B, theindividual components thereof being identified by corresponding, primedreference numerals. However, whereas the locking lever 85 is directedupwardly, the corresponding locking lever 85 is directed downwardly.

A lock-out arm 90, having spacing bushings 91 welded thereto, ismechanically keyed to the shaft 92 which is rotatable in the bearings 55and 56. As shown in FIG- URES 8-10, the lock-out arm comprises agenerally T-shaped member having a plurality of holes 93 formed thereinfor purposes of weight reduction. Secured to the integral side arms aretwo reversely-disposed pins 94 and 94'. Spaced sets of lugs 95 and 96are welded to the end of the lock-out arm, the lateral spacing betweenthe lugs corresponding to the width of a longitudinal slot formed in theend of the arm. One end of a fiat, flexure spring 97 is disposed withinsuch slot and secured in place by means of the screws 98. Visible inFIGURE 9, is the keyhole 99 which extends through the lockout arm andthe spacing bushings 91, such hole accommodating the shaft 92, seeFIGURE 3, and a steel key by means of which the lockout arm is securedto the shaft.

As shown in FIGURES 3 and 5, the free end of the flexure spring 97 isslidable between the surface of an L-shaped bracket 100 and a fiat bar101, the latter being secured to the bracket by bolts and cooperatingnuts. It

will be apparent that the lock-out arm 90 is secured to the shaft 92which is freely rotatable in the bearings 55 and 56, and that the armnormally is biased to the illustrated, horizontal position by thefiexure spring 97. The weight of the lock-out arm is counterbalanced bythe fiexure spring to provide high sensitivity and speed of action.

As stated hereinabove, the incoming cartons, transferred onto the belt21 from the two infeed conveyor lines A and B, enter the control stationin a haphazard manner. Assuming, now, that the moving carton 35a, inLine A, is the first to engage the projecting end 75 of the overlyinggate 63, such gate is rotated in a clockwise direction and remains inthe rotated position until the carton passes beyond the gate. Rotationof the gate 63 results in a corresponding rotation of the locking lever85. This causes the pin 94, carried by the lock-out arm 90, to move outof the detent 87 formed in the end of the lever 85. Simultaneously, thelock-out arm 90 is caused to rotate in a clockwise direction, therebyresulting in a movement of the pin 94 fully into the detent 87' formedin the end of the other locking lever 85. Since the pin 94 is locked inthe detent by the cam action of the lock-out arm, the other gate 63',associated with the line B, remains locked in its normal position, thatis, with the curled end of the gate projecting into the path of travelof the cartons. Thus, during the time the gate 63 is rotated out of itsnormal position by a carton 35a, the gate 63' will hold back any cartonsreaching it, such as the illustrated carton 35b. Upon release of thegate 63, the fiexure spring 70 returns the lock-out arm 85 to its normalposition, the two pins 94 and 94 again are partially disposed within thedetents of the associated locking levers 85 and 85', whereby eitherlever is free to rotate. Assuming that carbon 35b has been pressingagainst the gate 63 during passage of the carton 35a through the controlstation, the carton35b now causes a clockwise rotation of the lockinglever 85, thereby moving the pin 94 out of the detent 87' andsimultaneously moving pin 94 into the detent 87. Now, the gate 63 islocked in the normal position to block the movement of line A cartonsthrough the control station. Thus, cartons are alternately released fromline A and line B, under normal operating conditions, with such spacingthat they converge, without possibility of jamming, into a single lineunder the influence of the guide rails 27 and 28. When cartons arrive atthe control station back-to-back in a group on one of the lines, theassociated gate remains in the rotated position until the entire grouphas passed before allowing the release of cartons from the other line.As shown in FIG- URE 5, the maximum clockwise rotation of the lockinglevers 85 and 85 is limited by the setting of the stop screws 104 and104' carried by brackets which are secured to suitable members of thesuper structure.

The described control mechanism is of simple construction and operation,resulting in low manufacturing cost and negligible maintenance. Thecounter-balanced arrangement of the lock-out arm and the two lockinglevers reduces the inertia of these members, thereby affording highspeed operation without damaging cartons, or the outer carton wrapping,due to high impact of the cartons against the gate. The gates may alsobe provided with a resilient plate to further absorb shock and minimizecarton damage.

For use with unstable cartons, or packages, top and bottom gates may beprovided as shown in the fragmentary views of FIGURES 11-13. In FIGURES11 and 12, there are shown the gate bar 62, gate 63, locking arm 85, thefiexure spring 70, bearings 53 and 59, shaft 61, the short guide rail 31and the long guide rail 27, all of which are associated with the line Aof the control station, see also FIGURES 3 and 4. In this construction,however, the shaft 61 extends beyond the bearing 59, and spaced belts107 and 108 are provided for transporting the 6. line A cartons throughthe control station, one such carton C being shown in dotted lines. Itis here pointed out a belt similar to the end belt 107 is disposed atthe line B section of the control station with the center belt 108 alsospaced therefrom. These three belts pass around the end pulley 109 andmove at the same speed. A fourth belt 110, passing around the end pulley111, has a width substantially equal to the other three belts plus thespacing and may be driven at the same, or somewhat increased, speed.Cartons passing through the control station are guided by the guiderails 31 and 27..

Positioned below the belts 107 and 108 is a shaft 112, which isrotatable within the aligned bearings 113 and 114. Secured to this shaftis a bushing 115, as by the set screws 116, which bushing has weldedthereto a lower gate 117 having a curled end 118 normally extendingthrough the space between the belts 107 and 108. The shafts 61 and 112are mechanically-coupled together for simultaneous rotation but inopposite directions by the two crank arms 120 and 121 and a turnbuckle122, each such crank arm being secured to the associated shaft by meansof set screws.

Referring specifically to the fragmentary, side elevational view ofFIGURE 13, wherein the bearings are omitted for clarity of disclosure,the cooperating gates 63 and 117 are shown in the normal position withthe respective curled ends 75 and 118 extending into the path of travelof the carton C carried by the spaced, adjacently-disposed belts, onlythe end belt 107 being visible in this particular view. A clockwiserotation of the gate 63 and the supporting shaft 61, by the movingcarton C, results in the simultaneous clockwise rotation of the lockinglever and the counterclockwise rotation of the shaft 112 and thesupported gate 118. As the carton moves to the left, it is transferredonto the belt 108 for transport to the discharge end of the apparatus.During such movement of the carton, the upper gate 63 slide along thetop surface of the carton while the lower gate 117 slides along thebottom surface. In this arrangement, the fiexure spring 70 is designedto counterbalance the Weight of the entire rotatable assembly and theconstruction is such that the gates 63 and 117 exert equal pressureagainst the opposed carton surfaces. Such pressure balance permits highspeed operation with tall, relatively narrow cartons which otherwisemight be tipped over upon impact with the single, upper gate. A secondcontrol mechanism, similar to that shown in FIGURES 11-12, isoperatively associated with cartons passing through the line B sectionof the control station.

Having now described the invention, those skilled in this art will beable to make various changes and modifications without thereby departingfrom the scope and spirit of the invention as recited in the followingclaims.

I claim:

1. Apparatus comprising,

(a) a horizontally-disposed endless belt for receiving spaced row-s ofobjects,

(b) mean for moving the belt,

(c) means defining two parallel flow paths for the objects carried bythe belt,

((1) a pair of gate members positioned above the belt and individuallyrotatable about a horizontal axis,

(e) flat flexture springs carried by the gate members and biasing thegate members to normal positions wherein a portion of each gate memberextends downwardly for engagement by the objects carried by the belt,and (f) means effective upon rotation of one of the gate members tomechanically lock the other gate member against rotation.

2. The invention as recited in claim 1, wherein each of the said gatemembers comprises a gate arm secured to a shaft and carrying the fiexurespring; a gate having a curled end for engagement by the objects; andmeans securing the gate to the gate arm.

3. The invention as recited in claim 1, wherein the said belt comprisesthree laterally-spaced sections mounted for simultaneous movement in acommon plane, and including a second pair of gate members rotatableabout individual axes lying below the belts, each of said second pair ofgate members being aligned with corresponding ones of the first pair andhaving portions normally extending through the space between the beltsand into the path of travel of the objects; and individual meansmechanically coupling together the aligned gates of each pair forsimultaneous rotation in opposite directions.

4. The invention as recited in claim 1, including guide means fordirecting cartons which have passed the gate members into a single lineflow.

5. Carton combining apparatus comprising,

(a) a horizontally-disposed endless belt for receiving two spaced rowsof cartons at one end thereof,

(b) means for moving the belt,

(c) means defining parallel flow paths for the cartons carried at saidone end of the belt,

(d) a pair of gate arms each having one end secured to one of a pair ofaxially-aligned, rotatable shafts positioned over the belt,

(e) a gate carried by each gate arm and having a downwardly extendingend portion,

(f) spring means biasing each gate arm to a normal position wherein theend portions of the gates are engageable by cartons carried by the beltas they move along the said flow paths,

(g) a pair of spaced locking levers each having an end secured to one ofsaid axially-aligned shafts, each lever having a detent formed in thefree end thereof and terminating in an entrance wall,

(h) a vertically-disposed lock-out arm disposed between the said lockinglevers and rotatable about an axis parallel to that of the saidaxially-aligned shafts,

(i) a pair of pins carried by the lock-out arm and extending in oppositedirections therefrom, each pin being adapted to be received in a detentof an associated locking lever,

(j) spring means biasing said lock-out arm in a normal position whereineach pin is partially-disposed within the associated detent, and

(k) guide means for directing cartons which have passed beyond the gatesinto a single line at the other end of said belt,

the recited arrangement being such that rotation of one gate causes oneof the pins to move out of the detent of the associated locking leverand along the associated entrance wall, thereby effecting rotation ofthe lock-out arm in a direction to cause the other pin to seat with thedetent of its associated locking lever.

, 6. The invention as recited in claim 5, wherein the said spring meansbiasing each gate arm comprises fiat fiexure springs each having an endsecured to an associated gate arm, wherein the other end of each fiexurespring is restrained against displacement normal to the plane of thespring, and wherein each fiexure spring counterbalances the weight ofthe associated gate arm, gate and locking lever.

7. The invention as recited in claim 6, wherein the said spring meansbiasing the lock-out arm is a fiat fiexure spring having one end securedto the lock-out arm and the other end restrained against displacementnormal to the plane of the spring, and wherein the fiexure springcounterbalances the weight of the lock-out arm and the pins carriedthereby.

8. The invention a recited in claim 5, wherein the said belt comprisesthree laterally-spaced sections having upper surfaces movable in acommon plane, and including a second pair of axially-spaced rotatableshafts disposed below the upper surfaces of the belts; a gate secured toeach such shaft, each gate having an end portion normally projectingthrough the space between the belts; and individual means mechanicallycoupling together corresponding ones of the said two pairs of shafts forsimultaneous rotation in opposite directions.

References Cited UNITED STATES PATENTS 1,853,787 4/1932 Twomley 198323,064,792 11/1962 Brolf 198-32 EVON G. BLUNK, Primary Examiner.

EDWARD A. SROKA, Assistant Examiner.

1. APPARATUS COMPRISING, (A) A HORIZONTALLY-DISPOSED ENDLESS BELT FORRECEIVING SPACED ROWS OF OBJECTS, (B) MEANS FOR MOVING THE BELT, (C)MEANS DEFINING TWO PARALLEL FLOW PATHS FOR THE OBJECTS CARRIED BY THEBELT, (D) A PAIR OF GATE MEMBERS POSITIONED ABOVE THE BELT ANDINDIVIDUALLY ROTATABLE ABOUT A HORIZONTAL AXIS, (E) FLAT FLEXTURESPRINGS CARRIED BY THE GATE MEMBERS AND BIASING THE GATE MEMBERS TONORMAL POSITIONS WHEREIN A PORTION OF EACH GATE MEMBER EXTENDSDOWNWARDLY FOR ENGAGEMENT BY THE OBJECTS CARRIED BY THE BELT, AND